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Remember when I said I STILL wasn't done with this? Well, my gaunts have been bugging the crap out of me for a while now so I figured it was time to do something about it and...well, no time like the present, right?
Huge thanks to Art for generously posting up pics and measurements of the Cevantes gauntlets a few years back. I made good use of them. Here's the ROTJ set in progress. Styrene pieces and LOTS of time. Filled in the edges and gaps with Tamiya white putty
Next - primed and sanded
And the first cast

After that, I made a copy my original right upper and used that for a base with a few....ahem...adjustments

Hit it with a little primer to see where I was at -
And the first cast out of the mold -

And of course I had to redo the bottom shells. I used the existing bases and modified those.

And here are a few more shots of the individual uppers -

And a family ROTJ photo

In between these, I also managed to squeeze in a mod to my existing ROTJ flamethrower mold and add the nozzle tip flare to it. Pretty pleased with how it turned out

That's it for now. ESB upper left gaunt is finished, just needs to be molded. Lower ESB left gaunt clamshell buck is completed as well. Pics soon!

Thanks guys
I got ya covered sleep
Not quite ready for production on the ROTJ set yet. I need to order resin and shell shock (yes, I said shell shock), I will NOT be fiberglassing these. I have made a few out of resin and shell shock (the left gaunt pictured actually) and that stuff is fantastic.
Here's a sneak peek of the upper left ESB gaunt -
Just need to finish wet sanding and get this sucker molded up.
I'll also be making forming bucks of all these as soon as I get the chance, for those that want to go with vacc'ed gaunts only all the way around.

I've had a some people over the past few years asking me what the differences are between the ESB and the ROTJ left gauntlet (other than the flamethrower of course) and at the time (TBH) I really didn't know EXACTLY what they were.
But during my research while re-doing my V2 gauntlets I noticed some differences between the ROTJ and the ESB. The 4 main ones being:
1. The most obvious that everyone already knows - Sharp corners and edges on the ROTJ vs. the softer ones found on ESB (likely from the ESB being vacformed and the ROTJ being done in fiberglass (?))
2. Left 'flamethrower shelf edge' - being wider on ROTJ vs. the thinner ESB (I found out this one from Rafalfett, thanks again Levi)
3. Two squares below the dental expander area on the ESB version are not present on ROTJ
4. The front calc pad tray lip is present on ROTJ, but not on ESB. However, I believe the calc pad tray AREA is the same size on both.

To the best of my knowledge, these are the only differences between the two left gaunt upper clams (again, with the exception of the flamethrower). The PP1 left gauntlet (which has the ST flamethrower) is basically an ESB gaunt (it has all of the same characteristics I listed above), BUT it has the raised calc pad tray lip (notice the shadow line at the front of the calc pad in this pic, indicating a raised edge - http://www.thedentedhelmet.com/galle...-assembly.html).
The PP2 left gaunt is different entirely from all of the others (counting the PP1 and 3 as well) in which it appears vacformed, has the entire back area raised up where the rocket sits, has an added 'shelf' just under the rocket tip, a shortened calc pad area with no lip, and of course is painted yellow. The PP2, as we all know, is the one that appears on the Kenner packaging for the vintage figure. (pics found here - http://www.thedentedhelmet.com/galle...e-costume.html
and here - http://www.thedentedhelmet.com/galle...e-costume.html)
I also researched the right gauntlet and I didn't find any differences in those (again, to the best of my knowledge...that's my disclaimer and I'm sticking to it lol. Knowing RF, he'll come along and find something I missed ). I believe they used the same right gaunt for both ESB and ROTJ as well as for the PP versions. Thank GOD, cause I really don't want to make another version of that.
Here's a pic of my V2's compared side by side so you can see the differences -

In the interest of sharing information, any and all comments, observations, etc are welcome